Yarn Manufacturing Technology

Flow chart of carded yarn production:

Input Process/ Machine Output
Bale → Blow room → Lap
Lap → Carding m/c → Sliver
Sliver → Breaker Draw Frame → Sliver
Sliver → Finisher Draw Frame → Sliver
Sliver → Roving Frame → Roving
/Speed Frame/Simplex
Roving → Ring Frame → Yarn

Flow chart of combed yarn production:

Input Process/ Machine Output
Bale management
↓
Fibre → Blow room → Lap
Lap → Carding m/c → Sliver
Sliver → Pre comb drawing → Sliver
Sliver → Lap former → Lap
Lap → Combing → Sliver
Sliver → Post comb drawing → Sliver
Sliver → Simplex → Roving
Roving → Ring Frame → Yarn

Flow chart of Rotor yarn:

Input Process/Machine Output
Bale management
↓
Fibre → Blow room → Lap
Lap → Carding m/c → Carded sliver
Carded sliver → Draw frame → Drawn sliver
Drawn sliver → Rotor spinning → Rotor yarn

Bale management: Testing, sorting & mixing bales according to properties of fibre for producing
specific good quality yarn at minimum cost is called “Bale management”.

Importance of bale management:

If bale management is absent-
 Lot to lot variation will produce fabric barre effect.
 After weaving, shade variation will be found in case of dyed fabric.
 After knitting, colour variation may be found in case of dyed fabric.

Mixing: If different grade of same fibres are kept together, then it is called mixing.
 1  1 
e.g. 50% of 1 staple length of cotton + 50% of 1 staple length of cotton.
8 4
Types of mixing: Volume mixing, Wt. mixing, Hand stock mixing., Bin mixing, Mixing by hopper, Lap
mixing, Card mixing, Sliver mixing, Automatic mixing.

Blending: When different fibres of different grades are kept together, then it is called blending.

Blending is possible in different stages of Processes:

Blending type Process stage
Bale mixing - Before the blow room
Flock mixing - Within the blow room
Lap ,, - Using doubling scutchers
Web ,, - At the ribbon lap m/c or
the blending draw frame
Sliver ,, - At the draw frame & sliver
Lap or the comber
Fibre ,, - At the card or Rotor spgn m/c
Roving ,, - At the ring spgn m/c

Blow Room: Blow Room consists of a number of machines used in succession to open and clean the
cotton fiber to the required degree.
40 to 70% trash is removed in this section.
Operation in Blow Room:
I. Opening:
a. To open the compressed bales of fibers &
b. To make the cotton tuft a small size as much as possible.
II. Cleaning: To remove the dirt, dust, a broken seed broken leafs, stalks and another foreign material
from the fibers.
III. Bending or Mixing: To make good value of yarn and to decrease the production cost by mixing
different grade of fibers.
IV. Lap forming:
a. To transfer the opened and cleaned fibers into
a sheet form of definite width and uniform unit length which is called lap.
b. To roll the lap of predetermined length in a cylindrical shape around a lap pin.
c. To transfer the lap from the lap pin to a rod to suitable handle and feed it to subsequence
processing carding m/c.
Objects or Functions of blow-room:
The basic purpose of blow-room line is to supply following qualities of fiber tufts to the carding process.
 Small fiber tufts
 Homogeneously mixed or blended tufts
 Clean fiber tufts
 Convert fiber tufts into a fibrous sheet, is called lap.
Action in blow-room:
The actions of the machines in any blow room range fall into one or more of four main groups namely:
1. Action of opposite spike: (opening)
The action of opposite spikes is opening the cotton fiber. By this action, the large pieces of cottons have
been reduced in size.
2. Action of Air current: (Transport + Cleaning)
During processing, the movement of cotton from machines to machine is done by air current. It also helps
the separation of lint and trash.
3. Action of Beaters: (Cleaning & Opening)
Beaters are responsible for removing almost all of the impurity extracted in the blow room. Beater also
helps in opening of cotton fiber.
4. Action of regulating motion: (Uniform output)
The action of regulating motion gives the uniform output of cotton fiber by the help of swing door and
swing paddle
Carding: Heart of Spinning:
Carding is the one of the most important process in cotton spun yarn manufacturing, because it determine
the quality of yarn. This is the process, by which fiber are prepared to manufacture a yarn. In this process,
fibers are opened at almost single, removal of dust, trash, neps and short fiber to produce a continuous
strand of fiber called sliver. Carding machine is called heart of spinning, because it prepares the fiber in
such a way, which is ready to manufacture yarn because disentanglement, cleaning and intermixing of
fiber are happened here.

Objectives or Functions or Tasks of carding machine:

1. Opening the tufts into individual fibers and individualization of the cotton fiber at a single
fiber staple state.
2. Elimination of Impurities and dust: Elimination of foreign matter occurs mainly in the
region of the taker in.
3. Disentangling of neps i.e. removal of neps.
4. Elimination of short fibers.
5. Fiber blending.
6. Fiber orientation.
7. Finally produce a continuous strand of fibers called sliver of.
Draw frame
Drawing: It is a process of yarn manufacturing in which the sliver is elongated when passing through
pairs of rollers, each pair faster than the previous one.
This permits combination of several slivers and drawing and elongating them to straighten and to create
greater uniformity.

Necessity of draw frame or objectives of using Draw frame:

 Crimped, curled and hooked fibers are straightened,
 Parallelization of fibers,
 Reduction of sliver weight per unit length,
 Reduce irregularities of fibers by doubling and drafting,
 Remove remaining dust from sliver,
 Blending of fiber to provide compensation of raw material variation.

To parallisation of fibre and blending carded→ Carded sliver.

In carded sliver, fibre present in hook form i.e. trailing hooks and leading hooks.
To parallel those hook, draw frame is used.

Majority of the fibre hooks in a carded sliver are trailing while leading hooks are comparatively less.
Trailing hooks are also known Major hooks. While leading hooks are known as Minor hooks.

Tasks of draw frame:

I) Equalizing.
II) Parallelizing.
III) Blending.
IV) Dust removal.
Actions involved in Draw frame:
I) Drafting: The process of attenuating or increasing length per unit weight of sliver. It is mainly
due to peripheral speed of the rollers.
II) Doubling: The process of combing two or more carded sliver into a single form is called
doubling. In draw frame m/c generally six slivers are fed and converted into one i.e. six doubling.
III) Drawing: In the cotton Industry, the term is applied exclusively to processing on the draw frame,
where the operation is one of doubling and drafting.
Drawing = Drafting + Doubling.

Combing: Combing may be defined as to removed of short fibres , neps and remaining impurities of card
sliver by using comb with the help of knives , brushes and rollers.
Objects of combing:
1. To remove short fibres below a pre selected length so that the spinner enables to produce finer/
better yarn.
2. To remove reps and foreign matter from the sliver.
3. With the help of drawing and doubling, combed sliver is uniform and the fibres are straight and
parallel.
4. Improve the uniformity and strength of yarn
5. Improve yarn smoothness and lusture.
6. Reduce hairiness of yarn.

Objects / Necessity of lap former:

1. To reduce the strain to delicate comber reduce.
2. To reduce fibre damage.
3. To reduce chance of good fibres waste.
4. To reduce short fibres.
5. To reduce thick and thin places in the sliver.
6. To control wastage.
7. To parallel and straight of fibre in corded sliver by changing pushing of fibres .
8. Not freely opening of fibre from sliver.

M/c’s used for lap preparation :

1. Conventional system –
i. Sliver lap m/c.
ii. Ribbon lap m/c .
2. Modern System –
1) Super lap former

Object of pre comb drawing:

 To parallelize the hooked fibres
 To reduce the loss of long fibres
 To convert the leading hook into trailing hook
 To remove short fibres
Objects or functions of speed frame:
 Attenuation of drawframe, sliver to form roving of required hank by drafting,
 Insert small amount of twist to give required strength of roving,
 Winding the twisted roving on to bobbin,
 Build the roving in bobbin such a form, which will facilitate handling with drawing and transfer
to the next process.
Advantage of Ring spinning system:
 Any type of material (fibre) can be spun
 Wide range of count can be processed
 It delivers a yarn with optimum characteristics.
 Idealized twisting system
 It is uncomplicated and easy to operate
 Higher yarn strength can be achieved
Disadvantage of Ring spinning system:
 Low production
 Machine generates more heat

Limitations:
 In ring spinning machine twisting and winding are done simultaneously. That’s why the power
consumption is higher

Operation involved in ring frame

The Following Operation Are Involved:
I Creeling
II Drafting
III Twisting
IV Winding
V Building
VI Doffing

Main Features of Rotor spinning process:

 Yarn Coarser than carded or combed yarn

 Low count. Generally 12 to 20 English count
 Yarn Use for coarser fabric
 Low manufacturing coast.
 Produced by low graded fiber
 High productivity
 Less wastage percentage
 No need of Simplex machine
 Less labor
 High capital cost
 Mainly use to manufacturing Denim jeans fabric
 Low price
 Machine speed very high